Flooring material using poly lactic acid resin and construction methods of the same

ABSTRACT

Disclosed is a flooring material in which edge portions of a base layer and a surface layer of the flooring material are formed to be rounded when press forming the base layer and the surface layer, thereby providing its fine appearance, and which can provide construction joints between tiles through a dry construction method using an adhesive. The flooring material formed of a PLA resin, which is constructed on floor, includes a resin tile having a base layer and a surface layer which is stacked on the base layer and which consists of a dimensionally stabilizing layer, a balance layer, a printed layer, a transparent layer and a protective layer, the base layer and the surface layer being formed of the PLA resin and each four edge portion thereof being formed into a curved surface; and a construction joint which is formed at a gap formed between the tiles, wherein an adhesive is applied on the floor before the tile is attached, and the tiles are arranged to be spaced apart from each other with a desired gap therebetween, and the construction joint is formed at the gap.

TECHNICAL FIELD

The present invention relates to a flooring material using a natural resin, and more particularly to a flooring material in which edge portions of a base layer and a surface layer of the flooring material are formed to be rounded when press forming the base layer and the surface layer, thereby providing its fine appearance, and which can provide construction joints between tiles through a dry construction method using an adhesive.

The present invention relates to a flooring material formed of a PLA (Poly Lactic Acid) resin, which can provide environment-friendly base layer and surface layer stacked on the base layer, thereby being recyclable and rapidly decomposed upon the discarding thereof.

Further, the present invention relates to a construction method of the flooring material using the PLA resin, in which the adhesive is applied to the bottom portion of the tile, and the tiles are spaced apart from each other in a desired distance, thereby forming the construction joints between the tiles.

BACKGROUND ART

Generally, a tile is a plate type product which coats a surface of the floor, wall or the like, and it can be classified into an interior tile, an exterior tile, a mosaic tile, a acid resistant tile, a floor tile, a salt pond tile and the like according to its applications, and can be formed of a porcelain material, a stony material, a semi-porcelain material, an earthen ware material, a clay material and a synthetic resin according to its materials, and can be installed in a wet or dry construction method.

The dry construction method uses an adhesive. Herein, after the planarizing and cleaning processes of the floor or wall, the adhesive is applied thereon and then the tiles are attached thereon. The tile formed of the synthetic resin but not the ceramic material is mainly used.

Further, in a conventional resin tile used in the dry construction method, a base layer thereof is formed by rolling a polyvinyl chloride compound with a calender, and a printing hidden layer is formed by rolling a soft or hard polyvinyl chloride compound containing calcium carbonate as a filler, and an printed ink layer is formed on the printing hidden layer using transfer paper which is formed by directly performing a gravure printing process on the printing hidden layer.

And after a pattern protective layer for protecting the ink layer and an inside layer is formed by rolling a soft or semi-hard polyvinyl chloride compound, the inside layer, the base layer, the printing hidden layer and the pattern protective layer are stacked and then pressed by a laminating roll or a press.

However, in the above-mentioned tile construction method, since the wet construction method needs curing time, the construction period is extended and also the wet construction method needs a skilled person. Further, in case of the dry construction method, the construction period is short and the construction is simple, but since the tiles are installed without any gap therebetween, it is impossible to provide various expressions. Even though the tiles are installed with a gap therebetween like in the wet construction method, the external appearance is deteriorated due to the exposure of the printed layer and the base layer.

Further, in the conventional resin tile, since the base layer and the surface layer are formed of the polyvinyl chloride compound, it may be harmful to the human body. Further, since the edge portion of the tile has a square shape, the protective layer may be peeled off and thus the printed layer may be damaged as time passes.

DISCLOSURE OF INVENTION Technical Problem

An object of the present invention is to provide a flooring material which can form the construction joints between the tiles even though being installed by the dry construction method, and of which the base layer and the surface layer are formed of the PLA resin material which is environment-friendly and harmless to the human body.

Another object of the present invention is to provide a flooring material and a construction method thereof, in which edge portions of each tile are formed to be rounded so that the boundary of the surface layer is not exposed to the outside, thereby providing the fine appearance, and also in which the tiles are spaced apart from each other with a desired gap therebetween and the construction joints are formed at the gap.

Yet another object of the present invention is to provide a flooring material and a construction method thereof, in which the edge portions of each tile are formed to be rounded, thereby preventing the damage of the edge portion and also preventing the protective layer from being peeled off by many pedestrians.

Solution to Problem

To achieve the object of the present invention, the present invention provides a flooring material formed of a PLA resin, which is constructed on floor, including a resin tile having a base layer and a surface layer which is stacked on the base layer and which consists of a dimensionally stabilizing layer, a balance layer, a printed layer, a transparent layer and a protective layer, the base layer and the surface layer being formed of the PLA resin and each four edge portion thereof being formed into a curved surface; and a construction joint which is formed at a gap formed between the tiles, wherein an adhesive is applied on the floor before the tile is attached, and the tiles are arranged to be spaced apart from each other with a desired gap therebetween, and the construction joint is formed at the gap.

Further, the present invention provides a construction method of a flooring material formed of a PLA resin, comprising:

making construction floor even and removing foreign substances;

applying an adhesive on the construction floor;

attaching tiles consisting of a bottom layer, a base layer, a dimensionally stabilizing layer, a balance layer, a printed layer, a transparent layer and protective layer which are formed of the PLA resin and stacked in turn, such that the tiles are arranged to be spaced apart from each other with a gap therebetween; and

forming a construction joint at the gap between the tiles.

Advantageous Effects of Invention

According to the present invention, the flooring material is formed of the PLA resin material which is environment-friendly and harmless to the human body, it is possible to prevent environmental pollution.

Further, since each of the edge portion of the tile is formed to be rounded, it is possible to provide the fine appearance and also to prevent the protective layer from being peeled off by many pedestrians.

Further, since each of the edge portion of the tile forming the flooring material is formed to be rounded, it is possible to prevent the boundary of the surface layer from being exposed to the outside after the construction and thus to prevent the peeling of the protective layer because pedestrians could not step on the boundary of the surface layer, and it is also possible that tiles are spaced apart from each other with a desired gap.

Furthermore, since the construction joints which could be formed in only the wet construction method can be formed even in the dry construction method, it is possible to prevent the tiles from being separated by the contraction and expansion of the tile, it is possible to provide the various expressions, and it is also possible to simply construct the tiles.

BRIEF DESCRIPTION OF DRAWINGS

The above and other objects, features and advantages of the present invention will become apparent from the following description of preferred embodiments given in conjunction with the accompany drawings, in which:

FIG. 1 is a perspective view of a flooring material formed of a PLA resin according to the present invention.

FIG. 2 is an exploded cross-sectional view of a resin tile which is applied to the present invention.

FIG. 3 is a side view of the resin tile which is applied to the present invention.

FIG. 4 is a side view of a molding die for molding the resin tile according to the present invention.

FIG. 5 is a side view showing an example of a molding device for molding the resin tile which is applied to the present invention.

FIG. 6 is a cross-sectional view showing a construction process of the resin tile according to the present invention.

FIG. 7 is an expanded view of a main part of the present invention.

DETAILED DESCRIPTION OF MAIN ELEMENTS

-   10: tile 12: base layer -   14: bottom layer 20: construction joint -   30: surface layer 31: dimensionaly stabilizing layer -   32: balance layer 33: printed layer -   34: transparent layer 35: protective layer

BEST MODE FOR CARRYING OUT THE INVENTION

Hereinafter, the embodiments of the present invention will be described in detail with reference to accompanying drawings.

Firstly, FIG. 1 is a perspective view of a flooring material formed of a PLA resin according to the present invention, FIG. 2 is an exploded cross-sectional view of a resin tile which is applied to the present invention, and FIG. 3 is a side view of the resin tile which is applied to the present invention.

Further, FIG. 4 is a side view of a molding die for molding the resin tile according to the present invention, FIG. 5 is a side view showing an example of a molding device for molding the resin tile which is applied to the present invention, FIG. 6 is a cross-sectional view showing a construction process of the resin tile according to the present invention, and FIG. 7 is an expanded view of a main part of the present invention.

In the drawings, a flooring material 1 formed of a natural resin includes a tile 10 which is formed of a PLA resin, and a construction joint 20 which is formed between the tiles 10 after adhering construction of the tiles 10.

The construction joint 20 can be formed of white cement, an epoxy resin or other filler. The while cement is mixed with water when being used, and the epoxy resin is applied directly or indirectly using a gun.

The resin tile 10 basically consists of a base layer 12, a bottom layer 14 which is pressed to a lower surface of the base layer 12, and a surface layer 30 which is stacked on the base layer 12. The surface layer 30 includes a dimensionally stabilizing layer 31, a balance layer 32, a printed layer 33, a transparent layer 34 and a protective layer 35.

The base layer 12 is formed with a PLA (Poly Lactic Acid) resin using a press or roll pressing method.

The dimensionally stabilizing layer 31 of the surface layer 30 functions to reinforce the resin tile 10 and also to prevent a dimensional change thereof. The dimensionally stabilizing layer 31 is formed with the PLA resin. If necessary, glass fiber or non-woven fabric may be used as the dimensionally stabilizing layer 31. Further, the dimensionally stabilizing layer 31 also functions to prevent cracks generated upon using of the resin tile 10.

The bottom layer 14 formed on the lower surface of the base layer 12 and the balance layer 32 formed on the dimensionally stabilizing layer 31, which are formed of the PLA resin, function to maintain the balance of the bottom of the tile 10, i.e., the base layer 12, to reinforce the reality and provide surface properties, and also to prevent bending of the tile.

The printed layer 33 is provided with various patterns and designs which may be intaglioed or embossed using various colors. Recently, customized patterns or designs which are selected by a customer are printed thereon.

The transparent layer 34 formed of the PLA resin is to protect the printed layer 33, and wax is used as the protective layer 35.

Meanwhile, the PLA resin used in the present invention, which is a thermoplastic polyester resin of lactide or lactic acid, can be manufactured by polymerzing lactic acid prepared by fermenting starch extracted from corn or potatoes. Further, since the PLA resin can be recycled repeatedly, it is possible to solve the problems occurred by the exhaustion of resources, and emission of environmental pollutants is smaller than in other resins, e.g., polyvinyl chloride, and also it can be decomposed rapidly upon the discarding thereof.

The PLA resin can be classified into a crystalline PLA (c-PLA) resin and an amorphous PLA (a-PLA) resin. In case of the crystalline PLA resin, the bleeding that a plasticizer is flowed out onto a sheet surface may occur, and thus the amorphous PLA resin is used in the present invention.

When using the amorphous PLA resin, it is preferable to use 100% amorphous PLA resin. If necessary, a mixture of the crystalline PLA resin and the amorphous PLA resin may be used.

In the molding process, a non-phthalate plasticizer or an acrylic copolymer for reinforcing melt strength may be contained in the PLA resin.

A pair of or multiple pressing rolls or presses are used in the molding process. In the present invention, a molding device shown in FIGS. 4 and 5, which will be described later, may be used.

When forming the base layer 12, the bottom layer 14, the dimensionally stabilizing layer 31, the balance layer 32 and the transparent layer 34, one or more of a lubricant, a chain extender, a hydrolysis stabilizer or the like may be further added to the PLA resin.

That is, it is preferable in the base layer 12 that 5 to 100 parts by weight of the non-phthalate plasticizer is used with respect to 100 parts by weight of the PLA resin, 1 to 20 parts by weight of the acrylic copolymer is used with respect to 100 parts by weight of the PLA resin, and 0.01 to 10 parts by weight of the lubricant is used with respect to 100 parts by weight of the PLA resin.

Moreover, it is preferable that 0.01 to 10 parts by weight of the chain extender which functions to increase molecular weight and thus to improve tensile strength and heat-resisting property is used with respect to 100 parts by weight of the PLA resin, and 1 to 10 parts by weight of the hydrolysis stabilizer is used with respect to 100 parts by weight of the PLA resin.

In the dimensionally stabilizing layer 31, the balance layer 32 and the transparent layer 34, it is preferable that 5 to 60 parts by weight of the non-phthalate plasticizer is used with respect to 100 parts by weight of the PLA resin, 1 to 20 parts by weight of the acrylic copolymer is used with respect to 100 parts by weight of the PLA resin, and 0.01 to 10 parts by weight of the lubricant is used with respect to 100 parts by weight of the PLA resin.

And it is also preferable that 0.01 to 10 parts by weight of the chain extender and hydrolysis stabilizer are respectively used with respect to 100 parts by weight of the PLA resin.

Meanwhile, thermosetting or UV curable paint is used as the protective layer 35.

Preferably, the base layer 12 is formed to have a thickness of 1 to 3 mm, and the dimensionally stabilizing layer 31, the printed layer 33, the transparent layer 34 and the protective layer 35 are respectively formed to have a thickness of 0.01 to 1 mm, and the balance layer 32 and the bottom layer 14 have a thickness of 0.01 to 2 mm, respectively.

In the resin tile 10 of the flooring material 1 formed of a natural resin according to the present invention, the base layer 22, the dimensionally stabilizing layer 31, the balance layer 32, the printed layer 33, the transparent layer 34 and the protective layer 35 are continuously or independently formed by the pressing roll or press and then laminated by a molding device.

As shown in FIG. 4, a molding die 100 for pressing and laminating each layer is formed into a square container having an upper wall 120 and a side wall 140, and an edge portion in which the upper and side walls 120 and 140 are contacted with each other is formed to be rounded.

This is to form a curved surface 40 at each of the four edge portions of the tile 10 when the tile 10 is completed.

The curved surface 40 of the tile 40 is one of the features of the present invention, which provides fine appearance of the tile 10 and also allows a construction joint 20 to be formed. In other words, each end of the surface layer 30 of the tile 10 is located at the side portion of the tile 10, and thus the boundary of the surface layer 30 is not exposed to the outside after construction, thereby providing the fine appearance. Therefore, the tiles 10 can be constructed to be spaced apart from each other with a desired gap, and the construction joint 20 is formed at the gap, thereby preventing the tile 10 from being separated and also allowing the whole appearance of a flooring material 1 to be expressed variously.

FIG. 5 is a schematic view of a device for operating the molding die 100. The tile 10 is put on a transfer table 220, and the molding die 100 is fixed to a lifting part 240 so as to be lifted up and down, thereby press-molding the tile. The lifting part 240 may be a cylinder or other mechanical devices.

Of course, the molding device of FIG. 5 is an example, and other type molding devices and dies having different driving means may be used in the molding of the tile. Even in this case, each of the edge portions of the tile 10 has to be formed into the curved surface.

Hereinafter, the construction process of the present invention will be described.

First of all, in the present invention, the tile 10 is manufactured using the PLA resin.

The bottom layer 14, the base layer 12, the dimensionally stabilizing layer 31, the balance layer 32, the printed layer 33, the transparent layer 34 and the protective layer 35 are formed through the press rolling or pressing and then pressed and laminated through the molding device or other molding devices.

Herein, the four edge portions of the tile 10 are formed to be rounded, i.e., have the curved surface 40, and thus the boundary of the surface layer 30 stacked on the base layer 12 is not exposed to the outside, and also it is prevented that the boundary of the surface layer 30 is damaged by many pedestrians. Therefore, it is possible to prevent damage of the printed layer, the transparent layer and the protective layer.

In the construction of the flooring material, i.e., the tile 10, firstly, the floor on which the tile 10 is installed is made even and foreign substances are removed.

After removing the foreign substances, an adhesive is applied to the floor, and then the tiles 10 are attached thereon. Herein, the tiles 10 are arranged to be spaced apart from each other with a desired gap, and the constructions joints are formed at the gap.

Of course, if necessary, the tiles 10 may be attached without the gap.

White cement or epoxy resin is used in the forming of the construction joints. Further, the edge portions are formed into the curved surfaces 40, and the construction joints are formed up to the upper end of the surface layer 30 of which the boundary is located at the side surface of the tile 10, i.e., the boundary of the protective layer 30, thereby preventing the peeling of the surface layer 30 and the separation of the tiles 10.

INDUSTRIAL APPLICABILITY

The flooring material is formed of the PLA resin material which is environment-friendly and harmless to the human body, it is possible to prevent environmental pollution.

Further, since each of the edge portion of the tile is formed to be rounded, it is possible to provide the fine appearance and also to prevent the protective layer from being peeled off by many pedestrians.

Further, since each of the edge portion of the tile forming the flooring material is formed to be rounded, it is possible to prevent the boundary of the surface layer from being exposed to the outside after the construction and thus to prevent the peeling of the protective layer because pedestrians could not step on the boundary of the surface layer, and it is also possible that tiles are spaced apart from each other with a desired gap.

Furthermore, since the construction joints which could be formed in only the wet construction method can be formed even in the dry construction method, it is possible to prevent the tiles from being separated by the contraction and expansion of the tile, it is possible to provide the various expressions, and it is also possible to simply construct the tiles.

While the present invention has been described with respect to the specific embodiments, it will be apparent to those skilled in the art that various changes and modifications may be made without departing from the spirit and scope of the invention as defined in the following claims. 

1. A flooring material formed of a PLA resin, which is constructed on floor, comprising: a resin tile having a base layer and a surface layer which is stacked on the base layer and which consists of a dimensionally stabilizing layer, a balance layer, a printed layer, a transparent layer and a protective layer, the base layer and the surface layer being formed of the PLA resin and each four edge portion thereof being formed into a curved surface; and a construction joint which is formed at a gap formed between the tiles, wherein an adhesive is applied on the floor before the tile is attached, and the tiles are arranged to be spaced apart from each other with a desired gap therebetween, and the construction joint is formed at the gap.
 2. The flooring material according to claim 1, wherein the construction joint is formed at the gap formed between the tiles, such that the four edge portions of each tile is formed into the curved surface, and the construction joint is formed up to an upper side surfaces of the surface layer.
 3. The flooring material according to claim 1, wherein the construction joint is formed of white cement or epoxy resin.
 4. The flooring material according to claim 1, wherein one or more of the base layer forming the resin tile, a bottom layer pressed on a lower surface of the base layer, and the surface layer stacked on the base layer and consisting of the dimensionally stabilizing layer, the balance layer, the transparent layer and the protective layer are formed of the PLA resin.
 5. The flooring material according to claim 1, wherein the PLA resin contains one or more of a non-phthalate plasticizer, an acrylic copolymer for reinforcing melt strength, a lubricant, a chain extender, a hydrolysis stabilizer.
 6. A construction method of a flooring material formed of a PLA resin, comprising: making construction floor even and removing foreign substances; applying an adhesive on the construction floor; attaching tiles consisting of a bottom layer, a base layer, a dimensionally stabilizing layer, a balance layer, a printed layer, a transparent layer and protective layer which are formed of the PLA resin and stacked in turn, such that the tiles are arranged to be spaced apart from each other with a gap therebetween; and forming a construction joint at the gap between the tiles.
 7. The construction method according to claim 6, wherein the tile of which four edge portions are respectively formed into a curved surface are attached to the adhesive.
 8. The construction method according to claim 7, wherein the tile is pressed by a molding die in which each edge portion formed by an upper plate and a side plate, and the edge portions are respectively formed into a curved surface.
 9. The construction method according to claim 6, wherein the construction joint formed between the tiles is formed up to the protective layer which is the uppermost layer of the tile.
 10. A flooring material formed of a PLA resin, which is constructed on floor, comprising: a resin tile having a base layer, and a printed layer and a transparent layer which are stacked in turn on the base layer, one or more of the base layer, the printed layer and transparent layer being formed of the PLA resin and each four edge portion thereof being formed into a curved surface; and a construction joint which is formed at a gap formed between the tiles, wherein an adhesive is applied on the floor before the tile is attached, and the tiles are arranged to be spaced apart from each other with a desired gap therebetween, and the construction joint is formed at the gap.
 11. The flooring material according to claim 10, wherein a protective layer is stacked on the transparent layer.
 12. The flooring material according to claim 10, wherein a dimensionally stabilizing layer and a balance layer are stacked between the base layer and the printed layer.
 13. The flooring material according to claim 10, wherein a bottom layer is provided at a lower surface of the base layer.
 14. The flooring material according to claim 2, wherein the PLA resin contains one or more of a non-phthalate plasticizer, an acrylic copolymer for reinforcing melt strength, a lubricant, a chain extender, a hydrolysis stabilizer. 